Help required.. can anyone with a Zetec and a Fidanza flywheel installed on their car comment on this:

[Clarko]

5 years after trying to start my. Birkin S3 (first time trying)… I had run into a problem with the Omex 600 software not getting a strong enough signal from the Crank Position Sensor…

standard Ford sensor, yes in the correct metal

”bush” (manual)on the engine …

The “stat sync” in the software was NOT Switching to ON… ie it was not certain enough the the position of TDC to fire the spark and fuel….

I attached a cheap Chinese oscilloscope and CPS was certainly picking up the correct pattern…. But Stat sync was still not triggering…. Omex after examining all the info suggested perhaps the signal was not strong enough….

anyway it was winter and I threw my hands up in the air and gave up…. That was in 2020 and now 5 years later my wife wants the garage space so I posted it up for sale…. But thought it is going to be easier to sell IF I actually get it running…

so here I am back wondering if anyone with a similar setup has had an issue that they might have found a work around d for?

my current working thesis is that it is something to do  with the Fidanza flywheel or fitment?

the logic says there are soooo many Zetecs in Seven type vehicles, that a non starter should not be a game stopper?

If it was easier to drop the whole engine out of there I might have gone the route of swapping the flywheel for a Retroford lightened steel setup… and this might be still the only route to go

🤷🏻‍♂️

Amy help would be gladly received 

🙏

[Vovchandr]

I don't have first hand experience at all but my personal consultant of CGPT has potential advice. 

 

"

• Problem: Many Fidanza flywheels for Zetec engines don't have the OEM 36-1 trigger pattern, or the tooth size/spacing may be different.

• Effect: The crank sensor might pick up a signal, but it's not in the format the ECU expects. The OmeX 600 likely needs a proper 36-1 pattern with specific gap timing.

• Check: Compare the Fidanza flywheel’s trigger pattern (number of teeth, missing teeth, spacing) to the OEM Zetec 36-1 flywheel. If it's off-spec, the ECU can't sync." 

 

Otherwise there's this advice 

 

"Sensor Signal Too Weak or Wrong Type

Problem: Lightweight flywheels can reduce signal amplitude, especially if the trigger teeth are shallow or not ferrous enough.

 

Effect: The signal might look OK on a scope but be borderline for triggering the ECU reliably, especially at cranking speeds.

 

Check:

 

Measure signal with an oscilloscope during cranking (not just while spinning by hand).

 

Compare peak-to-peak voltage to your ECU’s required minimum (usually 2V+ for a VR sensor).

 

Use a scope to confirm a proper 36-1 waveform and missing tooth timing.

 

3. Sensor Air Gap Too Large

Problem: If the air gap between the crank sensor and the trigger teeth is too large, signal gets weak.

 

Check:

 

OEM Zetec sensors typically need a 0.

5–1.0 mm air gap."

 

[pethier]

Pardon my ignorance,

 

What is a Fidanza flywheel?

[11Budlite]

7 hours ago, pethier said:

Pardon my ignorance,

 

What is a Fidanza flywheel?

 

It's a brand of aftermarket flywheels and other parts: https://fidanza.com/fidanza-00-04-ford-focus-2-0l-z-tech-5-speed-aluminium-flywheel-186991/?srsltid=AfmBOopF6jxC5URC2tuvcxAR4dZ5e2JawZq2e80t1CppYJdR3DNHwSjj

 

I'm sure it was a rarity, but I had a rather negative experience with Fidanza 15 years ago: 

 

[Ferdl]

I have a Fidanza flywheel in my Zetec and I had to get it balanced because of the heavy vibrations. 
My recommendation after 20 years Seven ownership:

When using „performance“ parts the chances are great to get overprized crap, and that even happens when dealing with a company with a good reputation. So always check and measure the stuff you get, do NOT assume it is „ok“!

[Clarko]

On 6/4/2025 at 12:34 PM, Vovchandr said:

I don't have first hand experience at all but my personal consultant of CGPT has potential advice. 

 

"

• Problem: Many Fidanza flywheels for Zetec engines don't have the OEM 36-1 trigger pattern, or the tooth size/spacing may be different.

• Effect: The crank sensor might pick up a signal, but it's not in the format the ECU expects. The OmeX 600 likely needs a proper 36-1 pattern with specific gap timing.

• Check: Compare the Fidanza flywheel’s trigger pattern (number of teeth, missing teeth, spacing) to the OEM Zetec 36-1 flywheel. If it's off-spec, the ECU can't sync." 

 

Otherwise there's this advice 

 

"Sensor Signal Too Weak or Wrong Type

Problem: Lightweight flywheels can reduce signal amplitude, especially if the trigger teeth are shallow or not ferrous enough.

 

Effect: The signal might look OK on a scope but be borderline for triggering the ECU reliably, especially at cranking speeds.

 

Check:

 

Measure signal with an oscilloscope during cranking (not just while spinning by hand).

 

Compare peak-to-peak voltage to your ECU’s required minimum (usually 2V+ for a VR sensor).

 

Use a scope to confirm a proper 36-1 waveform and missing tooth timing.

 

3. Sensor Air Gap Too Large

Problem: If the air gap between the crank sensor and the trigger teeth is too large, signal gets weak.

 

Check:

 

OEM Zetec sensors typically need a 0.

5–1.0 mm air gap."

 

Thanks for this, AI at its best…. It’s the first reference I have seen to the shallowness of the trigger wheel that Fidanza attaches to the aluminum flywheel being a possible problem??

I am also back to playing with the air gap by trying to grind down the sensor and also the aluminum “Ford bush”.. crazy part is… the tolerance required by Omex for the air gap is 0.3-0.5 mm.

 

I am trying to work on a plan B…

My preference would be NOT to have to drop the engine out (I didn’t put it in so I am a tad intimidated by that) as I understand it EVERYTHING will have to come off that engine again first!

Does anyone have a video or reference they can suggest for removing engine from a seven?

 

If I did that then I guess Retroford in the UK for a new bush and

lightened steel flywheel? Or open to suggestions?

 

Or a new ecu sourced in North America?

any suggestions for that?

 

any other thoughts if you were wearing my shoes?

Thankyou to all for your kind responses

🙏